Flame-retardant alloy material for electric control box

Abstract

The invention relates to a flame-retardant alloy material for an electric control box, which is characterized by comprising the following raw materials in percentage by weight: 20% of polyvinyl chloride, 60% of ABS (acrylonitrile-butadiene-styrene) plastic and 20% of assistant bag, the flame-retardant PVC + ABS alloy material for the electric control box, which can be industrialized and has good flame retardancy, dimensional stability and impact strength, is realized, and the material cost is remarkably reduced. And the injection molding processing efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of engineering materials, and in particular to a flame-retardant alloy material for an electric control box. Background Art

[0002] Reducing the production cost of home appliances has become an urgent issue that needs to be addressed in the industry.

[0003] In the field of plastics, processing and modifying general-purpose and engineering plastics through methods such as filling, blending, and reinforcement to enhance their flame retardancy, strength, impact resistance, and toughness is now commonplace. PVC+ABS modified plastics, as one such type, not only achieve enhanced performance but also offer recyclability, reducing carbon emissions while maintaining material performance and product aesthetics. However, existing technologies for modifying PVC+ABS plastics face numerous limitations. For one thing, common modification techniques such as copolymerization, chemical modification, blending, and the addition of fillers can mostly only be implemented within PVC resin production plants, significantly limiting their application scenarios. Furthermore, some modification methods, due to their relatively simple equipment and production processes, struggle to meet the requirements of injection molding processes. With the development of the air-conditioning industry and growing awareness of the importance of harmonious development of plastic materials and the environment, fully utilizing the plasticity of plastics and extending their service life have become key demands. This has led to a growing market demand for PVC+ABS modified plastics, necessitating the emergence of more advanced and practical modification technologies. Summary of the Invention

[0004] The purpose of the present invention is to provide a flame-retardant PVC+ABS alloy material for an electric control box with good flame retardancy, dimensional stability and impact strength, while significantly reducing material costs and improving injection molding efficiency. It has the goals of cost reduction and efficiency improvement, energy conservation and emission reduction, green environmental protection and sustainable development, and significantly enhances the competitiveness of the product in the market.

[0005] To achieve the above objectives, the present invention provides the following technical solutions.

[0006] A flame-retardant alloy material for an electric control box, comprising the following components by mass percentage:

[0007] Polyvinyl chloride (PVC): 20% to 45%,

[0008] Acrylonitrile-butadiene-styrene copolymer (ABS): 45% to 60%,

[0009] Additive package: 10% to 20%;

[0010] The additive package includes an antioxidant, a heat stabilizer, a plasticizer and a lubricant, wherein:

[0011] Antioxidants account for 5% to 15% of the additive package.

[0012] Heat stabilizers account for 20% to 30%,

[0013] Plasticizers account for 30% to 45%,

[0014] Lubricants account for 15% to 30%.

[0015] Preferably, the plasticizer is dioctyl phthalate (DOP), and its usage is controlled to be no higher than 12% of the total material mass.

[0016] Preferably, the steps of preparing the material are:

[0017] A1: Accurately weigh the PVC and additive package according to the proportion and put them into a high-speed mixer. Mix them at 80°C for 15 minutes. The mixing motor current is 50Hz and the synchronous speed is 750 rpm.

[0018] A2: The mixed material was blended with ABS and fed into a twin-screw extruder. The temperature control zones were set to 160°C, 170°C, 180°C, 185°C, and 190°C in sequence, and the screw speed was 350 rpm.

[0019] A3: Flame retardant alloy material particles are obtained through melt blending, extrusion, cooling and pelletizing.

[0020] Preferably, by adjusting the screw kneading block angle to 60° staggered and setting the dispersion density to 8 blocks / 100 mm, the dispersion degree of the flame retardant in the matrix can be made ≥95%.

[0021] Preferably, the temperature in the melting zone is not higher than 200° C. to avoid excessive cross-linking of the ABS rubber phase, which may lead to a decrease in mechanical properties.

[0022] Correlation between process parameters and performance improvement

[0023] 1. Optimization of mechanical properties

[0024] Impact strength:

[0025] Optimization points: Melting zone temperature of 190°C + screw speed of 150RPM + kneading block stagger angle of 60° can disperse the ABS rubber phase in the PVC matrix with a particle size of ≤2μm (observed by SEM), and improve the impact strength by 20%–30%.

[0026] Tensile Strength:

[0027] Key parameters: metering zone temperature 180°C + screw speed 120 RPM to ensure uniform cooling of the melt and avoid strength fluctuations caused by inconsistent orientation.

[0028] 2. Optimization of flame retardant performance

[0029] Dispersion uniformity: A mixing zone temperature of 200°C, a rotation speed of 200 RPM, and a kneading block density of 8 blocks / 100 mm can ensure that the dispersion of flame retardants (such as decabromodiphenylethane) is ≥95% (detected by EDS surface scanning), and the flame retardant grade is increased from UL94 V2 to V0.

[0030] Thermal stability: The temperature of the feeding zone + compression zone is ≤170℃. When combined with 1% antioxidant and 3% heat stabilizer, the thermal decomposition starting temperature of PVC can be increased from 220℃ to 240℃ (TGA test), reducing the decomposition loss of flame retardants during processing.

[0031] 3. Processing efficiency optimization

[0032] Increased production capacity: By adopting a high-speed conveying section thread (lead 40mm) + medium-speed rotation speed (180RPM), the output can be increased from 50kg / h to 80kg / h. At the same time, the melt viscosity is controlled by the die head temperature of 185℃ to ensure stable discharge.

[0033] Reduced energy consumption: Optimizing the temperature control gradient (e.g., reducing the melting zone temperature by 5°C) and reducing the number of kneading blocks (from 10 to 6) can reduce the unit energy consumption from 3.5 kWh / kg to 2.8 kWh / kg.

[0034] The present invention has the following advantages

[0035] Improved impact performance: Through the reasonable ratio of PVC, ABS and additive package, the impact performance of the flame-retardant PVC+ABS alloy is significantly improved. Compared with traditional materials, it is less likely to be damaged when subjected to external impact, effectively ensuring the safety of the air-conditioning electronic control box during use. The synergistic toughening and dispersion process is adopted to make the ABS rubber phase dispersed particle size ≤2μm, and the impact resistance is improved by more than 20%.

[0036] 2. Improved heat resistance: The synergistic effect of additives such as heat stabilizers in the additive package significantly improves the heat resistance of the alloy material, enabling it to operate stably in high temperature environments and meet the strict heat resistance requirements of air-conditioning electronic control boxes. That is, the material's TGA initial decomposition temperature is increased to above 240°C, and its flame retardant effect is excellent, with an oxygen index (OI) of up to 29%, meeting UL94V0 grade requirements.

[0037] 3. Reduce shrinkage and increase dimensional stability: The unique formula design and preparation process effectively reduce the shrinkage of the flame-retardant PVC+ABS alloy, significantly improve the dimensional stability of the product, avoid assembly problems caused by dimensional changes, and ensure the accurate installation and normal operation of the air-conditioning electronic control box.

[0038] 4. Directly improve production efficiency: When the flame-retardant PVC+ABS alloy material of the present invention is used to replace traditional engineering plastics flame-retardant ABS and PC+ABS for injection molding production, the injection molding temperature can be reduced, the injection molding cycle can be shortened, the melt fluidity is good, and the injection molding cycle can be shortened by 20%, thereby greatly increasing the production capacity per unit time and improving the production efficiency of the enterprise.

[0039] 5. Directly reduce production costs: The price of the flame-retardant PVC+ABS alloy material of the present invention is only 60%-75% of the price of flame-retardant ABS and PC+ABS. Using this material to produce air-conditioning electric control boxes can directly reduce the comprehensive raw material cost by more than 30%, bringing significant economic benefits to the enterprise.

[0040] 6. Improve product quality: The molding process of flame-retardant PVC+ABS alloy material is significantly better than that of traditional materials. Using this material to produce air-conditioning electronic control boxes can effectively reduce abnormal conditions and defective rates in the production process, ensure the consistency and stability of product quality, and enhance the market reputation of the company's products. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 It is a schematic diagram of the process of the present invention.

[0042] Figure 2 This is a physical picture of the material of the present invention. DETAILED DESCRIPTION

[0043] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0044] See also Figure 1 , a flame retardant alloy material for an electric control box, the alloy material comprises the following components by mass percentage:

[0045] Polyvinyl chloride (PVC): 20% to 45%,

[0046] Acrylonitrile-butadiene-styrene copolymer (ABS): 45% to 60%,

[0047] Additive package: 10% to 20%;

[0048] The additive package includes an antioxidant, a heat stabilizer, a plasticizer and a lubricant, wherein:

[0049] Antioxidants account for 5% to 15% of the additive package.

[0050] Heat stabilizers account for 20% to 30%,

[0051] Plasticizers account for 30% to 45%,

[0052] Lubricants account for 15% to 30%.

[0053] Preferably, the plasticizer is dioctyl phthalate (DOP), and its usage is controlled to be no higher than 12% of the total material mass.

[0054] Preferably, the steps of preparing the material are:

[0055] A1: Accurately weigh the PVC and additive package according to the proportion and put them into a high-speed mixer. Mix them at 80°C for 15 minutes. The mixing motor current is 50Hz and the synchronous speed is 750 rpm.

[0056] A2: The mixed material was blended with ABS and fed into a twin-screw extruder. The temperature control zones were set to 160°C, 170°C, 180°C, 185°C, and 190°C in sequence, and the screw speed was 350 rpm.

[0057] A3: Flame retardant alloy material particles are obtained through melt blending, extrusion, cooling and pelletizing.

[0058] Preferably, by adjusting the screw kneading block angle to 60° staggered and setting the dispersion density to 8 blocks / 100 mm, the dispersion degree of the flame retardant in the matrix can be made ≥95%.

[0059] Preferably, the temperature in the melting zone is not higher than 200° C. to avoid excessive cross-linking of the ABS rubber phase, which may lead to a decrease in mechanical properties.

[0060] This embodiment provides a flame-retardant PVC+ABS alloy material for an electric control box. The material is composed, by mass, of the following components: 45% PVC, 45% ABS, and 10% of an additive package. The additive package contains various additives, including antioxidants, heat stabilizers, plasticizers, and lubricants. (The specific proportions of each additive in the additive package can be precisely adjusted based on actual performance requirements.)

[0061] Material ratio (mass percentage)

[0062]

[0063] 2. Equipment and process parameters

[0064] 1. High-speed mixer mixing step (A1):

[0065] Temperature: 80℃;

[0066] Mixing time: 15 minutes;

[0067] Motor frequency: 50Hz;

[0068] Speed: 750r / min (synchronous);

[0069] Operation: Put PVC and additive package into mixer and mix.

[0070] 2. Twin-screw extruder melt blending (A2):

[0071] Feeding order: Add A1 material and ABS at the same time;

[0072] Temperature zone settings:

[0073] Zone 1: 160°C

[0074] Zone 2: 170°C

[0075] Zone 3: 180°C

[0076] Zone 4: 185°C

[0077] Zone 5: 190°C

[0078] Screw speed: 350r / min;

[0079] Kneading block configuration: 60° staggered angle, density 8 blocks / 100mm;

[0080] Discharge: Extruded through the die head and then cooled and pelletized.

[0081] 3. Test Results

[0082] The prepared flame retardant alloy material was injection molded by standard spline (injection temperature: 180-190°C, mold temperature: 60°C), and the performance was tested as follows:

[0083]

[0084]

[0085] The flame-retardant PVC+ABS alloy material for the electric control box prepared in this embodiment significantly improves flame retardancy while ensuring processability and mechanical properties, and has the following advantages:

[0086] The flame retardant grade reaches UL94 V-0, meeting the safety requirements of electrical enclosures;

[0087] Impact resistance and dimensional stability are better than traditional flame retardant ABS;

[0088] The cost is more than 30% lower than that of flame-retardant PC+ABS;

[0089] The injection molding cycle is shortened and production efficiency is improved.

[0090] This material is suitable for products with high requirements for flame retardancy and impact resistance, such as air-conditioning electric control boxes, electrical appliance housings, and switch panels.

[0091] The above is a detailed description of the present invention in conjunction with specific embodiments, and the specific implementation methods of the present invention should not be considered to be limited to these descriptions. For those skilled in the art to which the present invention relates, any equivalent substitutions or obvious modifications that do not depart from the concept of the present invention and have the same performance or use should be considered to fall within the scope of patent protection of the present invention as determined by the submitted claims.

Claims

1. A flame retardant alloy material for an electric control box, characterized in that: The alloy material includes the following components by mass percentage: Polyvinyl chloride (PVC): 20% to 45%, Acrylonitrile-butadiene-styrene copolymer (ABS): 45% to 60%, Additive package: 10% to 20%; The additive package includes an antioxidant, a heat stabilizer, a plasticizer and a lubricant, wherein: Antioxidants account for 5% to 15% of the additive package. Heat stabilizers account for 20% to 30%, Plasticizers account for 30% to 45%, Lubricants account for 15% to 30%.

2. The flame retardant alloy material for an electric control box according to claim 1, characterized in that: The plasticizer is dioctyl phthalate (DOP), and its usage is controlled to be no higher than 12% of the total material mass.

3. The flame retardant alloy material for an electric control box according to claim 1, characterized in that: The preparation steps of the material are: A1: Accurately weigh the PVC and additive package according to the proportion and put them into a high-speed mixer. Mix them at 80°C for 15 minutes. The mixing motor current is 50Hz and the synchronous speed is 750 rpm. A2: The mixed material was blended with ABS and fed into a twin-screw extruder. The temperature control zones were set to 160°C, 170°C, 180°C, 185°C, and 190°C in sequence, and the screw speed was 350 rpm. A3: Flame retardant alloy material particles are obtained through melt blending, extrusion, cooling and pelletizing.

4. The flame retardant alloy material for an electric control box according to claim 3, characterized in that: By adjusting the screw kneading block angle of the twin-screw extruder to 60° staggered and setting the dispersion density to 8 blocks / 100mm, the dispersion degree of the flame retardant in the matrix can be made ≥95%.

5. The flame retardant alloy material for an electric control box according to claim 3 or 4, characterized in that: The temperature in the melting zone is not higher than 200°C to avoid excessive cross-linking of the ABS rubber phase, which may lead to a decrease in mechanical properties.

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